DE102017101897B4 - Process for manufacturing a component - Google Patents

Abstract

A method for producing a component (100) from at least two components (110, 120) to be glued together, characterized by the following steps: - Providing a first component (110) made of a fiber composite hybrid material consisting of alternating fiber and metal layers (112, 114 ) is formed and in which the fiber layers (112) have a fiber material and a matrix material of a fiber composite material, - providing at least one second component (120) which is attached to the first component (110) by means of an uncured adhesive layer (130) between the components ( 110, 120) is or is arranged, - preheating of the uncured adhesive layer (130) in at least one sub-area (160) by tempering one or more metal layers (114) of the fiber composite hybrid material of the first component (110) in at least this sub-area (160) is such that the adhesive layer (130) in this sub-area (160) has a higher surface adhesion than the uncured adhesive layer (130), without completely hardening, in order to fix the second component (120) to the first component (110), and - moving the fixed components (110, 120) into an oven (150) and tempering the fixed components (110, 120) to completely harden the adhesive layer (130) between the first component (110) and the second component (120) and the matrix material of the fiber composite hybrid material of the first component.

Description

The invention relates to a method for producing a component from at least two components to be glued together.

The use of fiber composite materials in the aerospace industry as well as in the automotive industry has established itself due to the advantageous properties of these materials. Nevertheless, such fiber composite materials are not free from disadvantages. With the use of fiber composite hybrid materials, which in addition to a fiber material also have another, non-fiber material such as metal, the advantageous properties of fiber composite materials can be combined with the advantageous properties of isotropic materials in order to compensate for the disadvantages of each individual material under certain circumstances to be able to.

A fiber composite hybrid material is a material that is formed from alternating fiber and metal layers, the fiber layers having a fiber material and a matrix material. The fiber materials can be conventional fiber materials for producing a fiber composite component, such as, for example, glass fiber materials or carbon fiber materials.

One of the best-known representatives of fiber composite hybrid materials is a glass fiber reinforced aluminum material (GLARE), in which layers made of a fiber composite material and an aluminum material alternate. Such glass fiber reinforced aluminum materials are now used in commercial aviation. Above all, the improved impact and crack behavior makes the material mix of these fiber composite hybrid materials particularly attractive for the construction of aircraft fuselages. For sufficient rigidity of the fuselage, it is reinforced by the integration of stiffening elements (so-called stringers), whereby the stringers are connected to the so-called skin field by gluing in an integral construction.

This requires a multi-stage autoclave process in which the skin area is first cured and then the stringers are integrated, fixed and completely glued. A new vacuum build-up is required for each step, which is very time-consuming and costly. In practice, the stringers are integrated onto the skin area using positioning aids in the form of pins that are arranged and integrated in the skin area. These are removed again after the multi-stage autoclave process, which makes a further process step necessary.

The preparation for the positioning of the stiffening elements and the multi-stage autoclave process result in long process times. The positioning pins and bores in particular make the process very time-consuming and complex, since the pins have to be integrated in the shell production, have to be removed again afterwards and the stringers have to be provided with positioning bores. The pins represent a high risk, especially for the vacuum build-up, since the pointed pins run the risk of damaging the vacuum foil.

From the DE 10 2011 112 520 A1 a method for producing a fiber composite component is known in which two fiber composite components are to be joined to one another by means of gluing. The adhesive material is heated with the aid of inductive heating in order to fix the two fiber composite components to one another.

From the DE 11 2007 000 526 B4 a method for fastening a nut to a workpiece having a hole is known, an adhesive bond being formed between the nut and the material.

From the DE 10 2012 112 313 A1 a motor vehicle body is known in which profiles made of fiber-reinforced plastic are glued with light metal nodes.

The object of the present invention is to specify an improved method for producing a component from at least two components to be glued together, in which at least one component is produced from a fiber composite hybrid material.

The object is achieved according to the invention with the method according to claim 1.

According to claim 1, a method for producing a component from at least two components to be glued to one another is proposed, with a first component made from a fiber composite hybrid material being provided according to the method. The fiber composite hybrid material is formed from alternating fiber and metal layers, the fiber layers having a fiber material and a matrix material of a fiber composite material. This can in particular be an electrically non-conductive fiber material.

Furthermore, at least one second component is provided which is or will be arranged with the first component by means of an uncured adhesive layer between the components.

In a first alternative, the first and the at least second component are provided separately from one another, the second component then being arranged on the first component by means of an uncured adhesive layer in an intermediate step by attaching the second component to the first component is joined and the uncured adhesive layer is provided between the first and second component. In a second alternative, the first component and the second component are provided like an already joined form, in which the second component is already arranged on the first component by means of the uncured adhesive layer.

Subsequently, in a first temperature control step or temperature control process, the uncured adhesive layer is tempered in at least one sub-area, preferably in several locally limited sub-areas (pre-heating) by tempering one or more metal layers of the fiber composite hybrid material of the first component in these predetermined sub-areas. The temperature control of the one or more metal layers takes place in such a way that the adhesive layer, at least in the specified subregions, has a higher surface adhesion than the uncured adhesive layer before the temperature control, without completely hardening. Only in this way is it possible for the second component to be fixed to the first component through increased surface adhesion. However, the adhesive of the adhesive layer must not cure completely because at this point in time the matrix material of the fiber composite hybrid material is also not yet hardened and both the adhesive layer and the matrix material of the fiber composite hybrid material are to be cured simultaneously in one process step (so-called co-bonding).

After the first tempering process (pre-tempering), the components fixed in this way are then moved into an oven and tempered in a second tempering process or tempering step, so that both the adhesive layer and the matrix material of the fiber composite hybrid material of the first component cure completely during this second tempering process. The temperature required for this, with which the matrix material and the adhesive layer are applied in the second temperature control process, is significantly higher than the temperature of the first temperature control step, in which the adhesive layer is temperature controlled in partial areas.

With the help of this method, it is possible for the first time, especially when manufacturing aircraft structures with stiffening elements, to dispense with the fixing pins for fixing the stiffening elements on the skin field, since during the joining of the stiffening elements (second building elements) on the skin area (first building element) the Stiffening elements takes place without having to harden the component in partial areas. Rather, the entire component can then be completely cured together in a single process step, so that only a single vacuum build-up is required. The disadvantages of the manufacturing process carried out in practice, known from the prior art, are thus eliminated.

The inventors have recognized that by tempering the metal layer of the fiber composite hybrid material, tempering the adhesive layer between the first and the second component can be brought about in such a way that the surface adhesion of the adhesive layer can be increased compared to the non-tempered adhesive layer, so that the components can be brought together fix. Such temperature control of one or more metal layers of the fiber composite hybrid material can take place, for example, by energizing the metal layers in the manner of resistance heating. In an advantageous embodiment, as will be shown later, this can also be achieved by inductive heating.

In an advantageous embodiment, the fiber composite hybrid material of the first component is a fiber-reinforced aluminum material, in particular a glass fiber-reinforced aluminum material (also referred to as GLARE), as it is increasingly used in the aviation industry. The second component can also have such a fiber composite hybrid material or consist of such or only of a pure metal material, for example aluminum.

In a further advantageous embodiment, the adhesive layer has a matrix material as the adhesive, so that the adhesive layer can also be cured in the second temperature control process step based on the same edge parameters in the oven. The adhesive layer is advantageously a matrix material, as is also used in the fiber composite hybrid material. In this way, both the matrix material of the fiber composite hybrid material and the matrix material of the adhesive layer between the first and the second component can be cured under the same process parameters.

In an advantageous embodiment, the metal layers of the fiber composite hybrid material of the first component are tempered in the first tempering process step in such a way that the adhesive layer in the at least one partial area is heated to a temperature between 40 ° to 70 ° C, preferably between 45 ° to 55 ° C. Especially in these temperature ranges a Matrix material as an adhesive layer improves surface adhesion such that the components can be fixed to one another without the adhesive layer being completely cured in the process. Rather, the tackiness of the adhesive layer increases in these temperature ranges, so that the component can be moved into an oven without having to fear that the second component will slip in relation to the first component. Not fully cured means in particular a cured state or polymerization state or crosslinking state of less than 80%, preferably less than 50%, particularly preferably less than 30%.

In a further advantageous embodiment, an alternating electromagnetic field is radiated into the first component in the at least one sub-area for inductive temperature control of one or more metal layers of the fiber composite hybrid material of the first component, whereby there is an interaction with the metal layers of the fiber composite hybrid material, such that eddy currents in the Metal layers are generated and the metal layers are heated in these areas in which the alternating electromagnetic field is radiated in the direction of the thickness. By heating the metal layers in these areas, the adhesive layer between the first and the second component is finally also heated, as a result of which the increased surface adhesion for fixing the second component is realized.

The inventors have recognized that when using a glass fiber reinforced aluminum material (GLARE) and an induction device to radiate an electromagnetic alternating field with a power of approx. 400 watts, less than 5 seconds are required to apply the adhesive layer in the specified sub-area of the Heat the component to approx. 50 ° C in order to fix the two components to one another. It is therefore particularly advantageous if the electromagnetic alternating field is irradiated for less than 10 seconds, preferably less than 5 seconds, per partial area.

In an advantageous embodiment, an induction device is provided which has an induction generator, an induction coil and a concentrator, the electromagnetic alternating field being radiated with the induction device provided.

• 1 schematische Darstellung des erfindungsgemäßen Verfahrens in einer Querschn ittdarstellung;
• 2 schematische, perspektivische Darstellung des Bauteils.

The invention is explained in greater detail using the attached figures. Show it:

• 1 schematic representation of the method according to the invention in a cross-sectional representation;
• 2 schematic, perspective representation of the component.

1 shows a component in a cross-sectional view 100 that consists of a first component 110 and a second component 120 will be produced. The first component 110 has a fiber composite hybrid material in which fiber layers are formed 112 and metal layers 114 alternate. On an outside 116 of the first component 110 becomes an adhesive layer 130 applied and then the second component 120 on the first component 110 joined. With the adhesive layer 130 it can be a matrix material, as in the fiber layer 112 of the first component 110 is provided.

With the second component 120 it can be, for example, an aluminum component. This in 1 The component shown is a wing shell with a reinforcing element, the skin field being the first component 110 represents, while the stiffening element through the second structural element 120 is formed.

With the help of an induction device 140 is now on discrete areas of the component 110 the adhesive layer 130 tempered in such a way that the surface adhesion of the adhesive layer 130 increased in this area compared to the other, non-tempered areas, so that the second component 120 with the help of this adhesive layer 130 initially fixed to the first component, but is still detachably arranged.

The component can then 100 in an autoclave 150 are retracted without the risk of the second component 120 compared to the first component 110 slipped.

The induction device 140 has an induction generator 142 on, which is a resonant circuit induction generator with an oscillator that can be based on the insulated-gate bipolar transistor (IGBT) technology. The induction generator 142 stimulates an induction coil 144 with an alternating voltage, the induction coil being electrically insulated by a housing or a sprue and optionally actively cooled. Due to the high power, the coil should have relatively large dimensions in order not to overheat. The stiffening elements to be glued have very small dimensions. Hence a concentrator 146 advantageous, which concentrates the magnetic field lines on the area to be heated. The use of the concentrator 146 is a matter of interpretation and is only an example here.

2 shows the component in a perspective view 100 , in which a second component 120 on the first component 110 was fixed. For this purpose, discrete areas 160 each with the help of the induction device 140 out 1 the adhesive layer between the first component 110 and the second component 120 tempered, so that in this area the adhesive layer has received a higher surface adhesion, so the second component 120 on the first component 110 to fix.

List of reference symbols

100

Component

110

first component

112

Fiber layer

114

Metal layer

116

Outside

120

second component

130

Adhesive layer

140

Induction device

142

Induction generator

144

Induction coil

146

Concentrator

150

Autoclave / oven

160

Section

Claims (7)

A method for producing a component (100) from at least two components (110, 120) to be glued together, characterized by the following steps: - Providing a first component (110) made of a fiber composite hybrid material consisting of alternating fiber and metal layers (112, 114 ) is formed and in which the fiber layers (112) have a fiber material and a matrix material of a fiber composite material, - providing at least one second component (120) which is attached to the first component (110) by means of an uncured adhesive layer (130) between the components ( 110, 120) is or is arranged, - preheating of the uncured adhesive layer (130) in at least one sub-area (160) by tempering one or more metal layers (114) of the fiber composite hybrid material of the first component (110) in at least this sub-area (160) is such that the adhesive layer (130) has a higher surface adhesion in this partial area (160) ng as the uncured adhesive layer (130), without completely curing, in order to fix the second component (120) to the first component (110), and - moving the fixed components (110, 120) into an oven (150 ) and tempering the fixed components (110, 120) for complete curing of the adhesive layer (130) between the first component (110) and the second component (120) and the matrix material of the fiber composite hybrid material of the first component. Procedure according to Claim 1 , characterized in that the fiber composite hybrid material of the first component (110) is a fiber-reinforced aluminum material, in particular a glass fiber-reinforced aluminum material. Procedure according to Claim 1 or 2 , characterized in that the adhesive layer (130) has a matrix material as the adhesive material. Method according to one of the preceding claims, characterized in that the one or more metal layers (114) of the fiber composite hybrid material of the first component (110) are tempered in such a way that the adhesive layer (130) in the at least one partial area (160) to a temperature between 40 ° to 70 ° C, preferably between 45 ° to 55 ° C, is tempered. Method according to one of the preceding claims, characterized in that an electromagnetic alternating field is radiated into the first component (110) in the at least one sub-area (160) for inductive temperature control of one or more metal layers (114) of the fiber composite hybrid material of the first component (110). Procedure according to Claim 5 , characterized in that an induction device (140) is provided which has an induction generator (142), an induction coil (144) and a concentrator (146), the electromagnetic alternating field being radiated by means of the induction device (140) provided. Method according to one of the preceding claims, characterized in that the component (100) to be produced is an aircraft component in which the first component (110) is a flat aircraft structure on which a plurality of stiffening elements are arranged and glued as second components (120) .

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